Project Portfolio
Will Dale
Willdale1388@gmail.com │ (781)-915-9186
This portfolio gives a brief overview into the major engineering
projects I’ve completed within the past 2 years.
Main Projects Include:
• 3-Seater Electric Vehicle Design and Fabrication (Summer 2022)
• Infinity Mirror Table (Summer 2022)
• 3D Printed and Fiberglassed Wakefoil V1 (Summer 2021)
• Circus Stunt Swing (Summer 2021)
1
3-Seater Electric Vehicle Design and Fabrication
• Designed a steel frame to contain a drivetrain and steering system that fits under
an old couch using Solidworks.
2
3-Seater Electric Vehicle Design and Fabrication
• Researched and built the drivetrain
system including two 3000W motors,
a jack shaft, mechanical disc brake,
and a live rear axle.
3
• Designed and assembled a power
steering system using a linear actuator all
controlled wirelessly through a PS4
controller and ESP32 microcontroller
coded in C/C++.
3-Seater Electric Vehicle Design and Fabrication
4
• Built a battery using 320 18650 cells with a
nominal voltage of 72V that is capable of
drawing 150 amps continuously and has a
capacity of 41Ah. (Equipped with battery
management system)
• Soldered all the electronic components
including a digital potentiometer, 2 step
up converters and an ESP32 to a
protoboard.
3-Seater Electric Vehicle Design and Fabrication
5
• Designed a circuit to power a horn, 2 speed controllers, 2
motors, a linear actuator, LED light under glow, a USB charging
port and battery meter; using a combination of MOSFETS,
voltage converters, microcontrollers, switches, digital
potentiometers and more.
3-Seater Electric Vehicle Design and Fabrication
6
Conclusion: I ended up with a PS4 remote controlled couch capable of moving 1,000 pounds at a
speed of about 12 MPH with a battery range of 11 miles on a full charge.
What I Learned: This project allowed me to build upon many skills such as 3D modeling, coding
(C/C++), motor control, rapid prototyping, embedded systems, battery systems, welding, time
management, budget management and more.
Infinity Mirror Table
7
• Created a CAD model of a broken table I
had using Solidworks and then designed
an integrated system to create the infinity
mirrored effect.
• The CAD model shows the exploded view
of the main components including the
glass pane, solar mirror film, mirror and
frame.
Infinity Mirror Table
8
• Built a circuit to power four led
strips and one set of florescent
lights, all wired to a 3D printed
switch box.
• Used a combination of tools and
machines such as a table saw, a
router, a dremel, chisels,
sanders, a multimeter, a
soldering iron, a 3D printer, a
drill press and more.
Infinity Mirror Table
9
Conclusion: I ended up with a table that when turned ON, creates an ”infinity mirror effect”
which gives the illusion that the LED’s travel infinitely far into the floor.
What I Learned: This project further developed my skills in Solidworks modeling, circuit
building and woodworking / machine shop use.
3D Printed and Fiberglassed Wakefoil V1
• 3D modeled a wakefoil on Solidworks using a
basic airfoil shape as a starting point. I designed
the wing to fit with my existing wakefoil board
setup.
• Perfomed a Solidworks flow simulation on the
wing to generate an aerodynamics analysis
which calculated the lift and drag of the wing.
• Sliced the model into 9 different parts so I could
print them on my 3D printer.
10
3D Printed and Fiberglassed
Wakefoil V1
11
• 3D printed the 9 wakefoil parts using ABS
as the material.
• Connected the pieces together using
wooden dowels and epoxy.
• Fiberglassed the wing using 4oz fiberglass
cloth and marine epoxy.
• Filled all the imperfections of the wing
using Bondo and sanded it down smooth.
3D Printed and Fiberglassed Wakefoil V1
Conclusion: I ended up with a meter long wakefoil wing that was mildy successful
as I was able to achieve a 30 second ride. However, the wing was a little too flexible
and therefore caused instability.
What I Learned: This project further developed my skills in Solidworks modeling,
rapid prototyping, fiberglassing and machine shop use. I learned that fiberglass is
actually quite flexible and a fiber such as carbon would provide a more rigid wing
for version 2.
12
Circus Stunt Swing
13
• Designed a stunt swing made of wood timbers and
other components such as bearings, metal
brackets and a steel rod.
• The swing consists of 3 main parts, two triangular
support structures with a middle swinging
platform.
Circus Stunt Swing
14
Conclusion: I ended up assembling the 14-foot-
tall structure on my parent's dock and used it
to jump into the water.
What I Learned: This project further developed
my skills in using shop tools, rapid prototyping
and force/moment calculations.
